Method of making corrugated coil separators for annealing stacks



Dec. 18, 1962 Filed June 1, 1961 M. L. JACOB METHOD OF MAKING CORRUGATED COIL SEPARATORS FOR ANNEALING STACKS 5 Sheets-$heet 1 INVENTOR. Maze/s l Jacoa Hi5 ATTORNEY Dec. 18, 1962 M L JACOB 3,068,553

METHOD OF MAKING ORiKUGATED COIL SEPARATORS FOR ANNEALING STACKS Filed June 1, 1961 3 Sheets-Sheet 2 I IN VEN TOR. MaRfi/S L. Jncoa HAS A rraRA/EY M L JACO 3,068,553

' B METHOD OF MAKING CORRUGATED COIL SEPARATORS FOR ANNEALING STACKS Dec. 18, 1962 Filed June 1, 1961 s sheets -sheet s INVENTOR. MOfiR/JLJA cab His A T'TOEA/EY United rates This invention relates generally to method of making corrugated coil separators for spacing subjacent coils in an annealing stack and to the construction of such separators.

There are many difierent forms of separators. Some have top and bottom plates with spaced ribs therebetween. Others have a central plate with ribs on both sides. Others have wedge-shaped ribs secured by an annular ring. Each-of the known forms are not structurally sound. They warp, the ribs grow and get caught by the annealing cover. They fold out of shape and are not usable. In most instances they cannot conduct the gases properly to a stack of closed or open wound coils and they mark the edges of the same.

The principal object of this invention is the method of forming a separator plate that is strong, rugged, will not grow out of shape and may be handled when hot. These factors are in the method and construction of these separators. The separators comprising this invention are made of heavy plate which is formed into corrugations. When a single plate is corrugated the metal has to move and readjust to the new shape. The ring actually gets smaller when corrugated. Being made from one piece of steel a fiat ring of the same size will distort to make a round hole into an oval hole. However, with this structure the corrugations move or work the steel cold and the connecting sides whether vertical or sloping are all the same length and same depth for their full length and lie radially of the ring. The fact that the top and bottom flat surfaces of the corrugations are wedge-shaped, it is almost impossible for this integral structure to distort after reheating many times. The

flat wedge shape surfaces reinforced by the uniform connecting walls all combine to aid each other in providing strength and preventing distortion; In other words, this structure provides a built-in expansion and contraction pattern that provides the best possible restraint against distortion. This form of separator made completely from welded plates with each surface representing a different plate such as two wedge-shaped plates and two connecting plates forming a complete wave or cycle in the corrugation requiring four welded joints the full width of the ring, and with nine complete corrugations in the ring there would be thirty-six welds to form the ring and eighteen more to insert the ribs. This is an expensive process and the different plates if of different heats would react and twist the structure out of shape whereas the single plate or corrugated sections put together even if only one corrugation was made for each section would include only nine welds and eighteen welds for the ribs. It is preferable to form the corrugations in a single plate, a pair of half plates or in thirds. This materially reduces the cost and the least number of parts provides the best structure for the built-in expansion and contraction advantages.

If the upstanding radially disposed weight supporting rib in the trough of each corrugation were not employed, long use in annealing stacks would cause these surfaces to buckle in shortening the ring. This is because the gap of the wedge-shaped trough is too wide adjacent the perimeter. This only happens for a distance from the perimeter toward the center of the ring. This rib thus atent need not extend to the perimeter and it runs about twothirds the length of the corrugations. If the corrugation is about eight inches across the perimeter of the ring the inner may measure two and one-half to three-eighths inches and the rib being a half-inch in diameter will run to where the trough is four inches across which is sufiicient to bridge the gap and support the whole of the annealing load of the tall stack of coils. These ribs are preferably as thick as the corrugated plate. Theyare preferably one inch thick and at least a sixteenth of an inch below the top flat surface of the corrugations which overall may measure approximately two and one-sixteenth of an inch from one top surface to the other. When the edges of these ribs are rounded they will not mark the coil ends. However, these corrugated plates are permitted to breathe due to this one-sixteenth of an inch difference from each rib to the top of the adjacent fiat surface.

Another important feature of this invention is the pro-.

vision of a corrugated separator that has alternate corrugations faced in opposite directions to more efficiently conduct the heat to the coils. This is because this separator employs all three modes of transferring heat and the largest areas, the flat supporting surfaces, are responsible for this heat transfer. First the flat surfaces forming the corrugations provide a wide and wedge type conduit through which the gasses are directed, and the coils are thus heated directly in each direction convection for half the surface of the separator. Thus heating by convection. the coil ends heats this coil end by conducting the heat therethrough directly to the engaged end of the coil. Thus heating by conduction. The last phase is heating the coils by radiation. If the coils are open or loose wound then some radiation takes place on they contacting side of the fiat corrugation surfaces. Thus this form of separator is more efficient in transferring heat to the coils than any other form and they do not grow or become distorted as do the separators presently used. They provide the maximum exposure to both directions to the adjacent coils they separate. The radiation is thus from both sides of the corrugated plate.

Other objects and advantages of the invention appear hereinafter in the following description and claims.

The accompanying drawingsshow for the purpose of exemplification without limiting this invention or the claims thereto, certain practical embodiments illustrating the principlesofthis invention; wherein FIG. 1 is a perspective view of a corrugated coil separator plate comprising this invention.

FIG. 2 is a perspective view of a corrugated coil separator plate made in two parts.

'FIG. 3 is a perspective view of a corrugated coil separator plate made in three parts.

FIG. 4"is an enlarged view of the edge of a corrugated coil separator plate showing the ribs lower than theiadjacent flat surfaces. j j

FIG. 5 isa perspective view of the corrugated coil separator.

FIG. 6 is a perspective view of a coil separator plate with a modified corrugation form.

Referring to FIG. 1 the coil separator 1 is made of heavy plate in order to supply sufiicient strength when corrugated to support the coils being annealed at the highest annealing temperatures. The plate 1 is annular in form having. an outer perimeter 2 and an-inner central opening 3. The plate is'corrugated, the corrugations being dispersed radially, sectorlike, from perimeter 2 to Next the fiat surface that engages The heavy plate forming the corrugated coil separator as I in the radial plane of the great diameter of the separator which originally separated the two halves.

In FIG. 3 the corrugated coil separator is made in three parts originally separated along the lines 13, 15 and 16 each of which represents a radial plane originally dividing the corrugated coil separator in three equal parts.

In the structures of FIGS. 1 to 3 the corrugations may be formed by a single stamping, selectively or progressively. After the parts as shown in FIGS. 2 and 3 are completed then they are welded along their respective lines to produce a single unitary structure. A ring plate severed at one radius has been corrugated, trimmed and welded.

The corrugated structures shown in FIGS. 1 to 4 have a rectangular cross section with alternate top surfaces 4 and bottom surfaces 5 providing for the coil engaging surfaces when inserted between subjacent coils in an annealing stack. As shown in FIG. 4, alternate corrugations 4 and 5 provide substantially vertical walls 6 therebetween with the corners 7 rounded. These corrugations may vary in size, although it is preferable to make the alternate corrugations 4 and 5 substantially the same size so that an even distribution of the hot annealing gases may be exposed to the top of the under coil as well as to the bottom of the upper coil between which the separator plates are inserted. Thus, as shown in FIGS. 1 to 3, the alternate corrugations 4 and 5 are made uniform and are substantially the same size.

The channels 8 and 9 forming the interior of the alternate corrugations 4 and 5 must reduce in cross-sections as they approach the central opening 3 in order to provide a uniform distribution of the alternate corrugations in' the complete circular flat as shown in FIGS. 1 to 3. The inner ends 10 and 11 of the channels 8 and 9 are limited in size, and if they become too restricted to the flow of gases therethrough, it is necessary to reduce the number of alternate corrugations in the annular plate 1. Thus, the number of alternate corrugations is limited not only in their cross-sectional size, but also the diameter of the central opening 3.

' FIGS. 4 and 5 show the modification'employing the use of the upstanding radial reinforcing rib-12 each in a selected of the alternate corrugations which in this in stance is each of the channels of corrugations. Each of these upstanding radial ribs 12 as shown are solid bars and are preferably made no less than the thickness of the plate 1. However, they may be made thicker than the plate 1. The depth of the upstanding reinforcing rib 12 is preferably slightly less than the depth of the corrugation between the alternate flats 4 and 5 as illustrated in FIG. 4. ,This permits the coil engaging surfaces 4 and 5 to engage in support of the subjacent coils and the upstanding reinforcing rib 12 will not come. into play unless there is a slight sag in the corrugations of theplate 1. As shown the difference in the depth of the upstanding reinforcing rib 12 in the bore of corrugation may be as much as one-sixteenth inch with the corrugations being anywhere upto seven inches deep.

As shown the upstanding ribs 12 do not come to the outer perimeter 2 of the corrugated coil separator and they extend toward the center of the same for approximately two-thirds the distance as illustrated in FIG. 5;

4 whereas the opening of these corrugations illustrated on the inner or central opening 3 at 10 and 11 is approximately two and one-half to two and three-eighths inches across. The wide or heavy bar 12 preferably has rounded corners as indicated at 18.

Referring to FIG. 5 the upstanding reinforcing rib 12 is actually shorter than the trough 11 as indicated in the drawing. This permits the corrugations to actually pro tect the ends of the upstanding reinforcing rib 12 and when the plate 1 is handled or moved or positioned the ends of these upstanding reinforcing ribs are not likely to become bumped or otherwise disturbed, and they function solely to provide additional support of the weight of the coils when the annular separator plate 1 sag somewhat due to continuous reheating in annealing furnaces.

As illustrated in FIG. 5 the corrugated coil separator 1 may be made in nine sections each of which includes a complete corrugation 5 with a half corrugation 4 on each side thereof providing the marginal radial edges 29 and21. In this instance there would be a total number of nine welds to complete the unitary corrugated coil separator 1 whereas in the structure of FIGS. 2 and 3 there are two and three welds respectively to complete the ring shaped coil separator.

If it is desired to make the separator plate with more corrugations this may be accomplished by employing an arcuate shaped corrugation which substantially simulates the sine wave as shown by the corrugations 22 and 23 in FIG. 6. However, such a corrugation provides a narrower surface engaging flat between upstanding walls as illustrated in 24 and 25. These narrow flats also diminish adjacent to the central opening 3 as shown in FIG. 6. This corrugated structure which more nearly approaches the sine wave provides considerable strength in the structure of the corrugations and more corrugations may be provided in an annular plate of given diameter. Even though the coil engaging surfaces 24 and 25 are smaller, they are more in number and provide a good weight bearing surface that prevents the marking of the ends of the coil whether it be loosely or tightly wound. corrugations of this character need not be provided with upstanding reinforcing ribs.

Again the rounded portions of the corrugations shown in FIG. 6 allow a greater exposure of the gases to the coil ends and since the flat supporting surfaces 24 and 25 are adequate with the aid of the upstanding rib 12 this provides a good alternate structure. The purpose here 10 and 11 at the inner or central opening 3, yet the corrugations 22 and 23 are closer together.

Although the reinforcing members 12 and 15 are shown shorter than the length of the corrugations 4 and 5 they may very well extend to the inner and outer edges of this ring separator. The principal limitation is the smallness of the opening, as it is desired to promote free passage of gases at the inner and outer edges of the ring sepa rator.

I claim:

1. Method of forming a coil separator which cornprises cutting relatively heavy plate into the form of a flat ring of one or more pieces with predetermined inner and outer edges to provide a central opening and perimeter respectively, said cutting severing said ring along at least one line between said opening and'said perimeter, deforming said plate into sector-like corrugations extending substantially radially between said opening and perimeter with each corrugation comprising a flat and gene'rally upstanding Walls to define a channel on the interior thereof wider toward said perimeter and narrower toward said opening to conduct gases therethrough, alternate corrugations having their respective flats in axially spaced planes at the top and bottom of said plate respectively, said deforming simultaneously forming rounded outer corners along the edges of each fiat and substantially tangential thereto and to said walls respectively, and joining said plate along said line to provide a unitary coil separator.

2. Method of forming a coil separator as set forth in claim 1, comprising, said deforming of said plate providing sector-like corrugations of substantially the same size, afiixing upstanding ribs generally centrally and radially to the bottom of said channels respectively, each rib being wholly within its channel.

3. Method of forming a coil separator as set forth in claim 1, comprising, said cutting severing said flat ring along at least one radius extending from said opening to said perimeter, said joining said plate along said line comprising welding said plate along said radius, and aflixing an upstanding rib radially along the center of and wholly within each channel somewhat inwardly of and nearer said perimeter and extending for a major part of the radial dimension of said ring, said radius coinciding with the position at which one of said ribs is so afiixed.

4. Method of forming a coil separator which comprises cutting relatively heavy plate into the form of a flat circular ring of one or more pieces with inner and outer edges following predetermined acruate curves to provide a central opening and perimeter respectively, severing said ring along at least one radius extending between said opening and said perimeter, deforming said plate into sector-like corrugations of substantially equal size extending radially between said opening and perimeter with each corrugation comprising a fiat and generally radial walls substantially normal to said flat to define a channel on the interior thereof substantially rectangular in cross section and wider toward said perimeter and narrower toward said opening to conduct gases therethrough, al-

ternate corrugations having their respective flats in axially spaced planes at the top and bottom of said plate respectively, said deforming positioning said radius within a flat and simultaneously forming rounded outer corners along the edges of each fiat and substantially tangential thereto and to said walls respectively, and welding said plate along said radius to complete a unitary coil separator.

5. Method of forming a coil separator as set forth in claim 4, comprising, Welding an upstanding rib having rounded outer longitudinal edges and a lesser height than the depth of a channel radially along the center of the bottom of each channel for a distance approximating twothirds of the radial dimension extending substantially from said perimeter toward said opening.

6. Method of forming a coil separator as set forth in claim 5, comprising, positioning said radius radially in the center of a flat to coincide with the radial position of said welding of a rib.

References Cited in the file of this patent UNITED STAT ES PATENTS 819,340 Coe May 1, 1906 1,159,322 Livingston Nov. 2, 1915 1,190,572 Miller July 11, 1916 1,581,488 Lewis Apr. 20, 1926 1,599,801 Vreeland Sept. 14, 1926 1,663,151 Armstrong Mar. 20, 1928 2,646,762 Ingraham July 28, 1953 2,671,656 Winder Mar. 9, 1954 2,904,325 Jones Sept. 15, 1959 2,981,530 Menough Apr. 25, 1961 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent N00 3 O68 553 December 18 1962 Morris Lo Jacob appears in the above numbered pat It is hereby certified that error (1 Letters Patent should read as ent requiring correction and that the sai corrected below.

Column 5 line 22, for "acruate" read a'rcuate Signed and sealed this 10th day of December 1963.,

(SEAL) Attest:

EQDE J FIH -EJ- NGLDS ERNEST Wa SWIDER Acting Commissioner of Patents Attesting Officer 

